Abstract
Cutting force is the most fundamental, and essential for machining error control, chatter stability analysis and milling process planning. In this paper, a method to predict the cutting force for the milling with variable-pitch or variable-helix cutter is provided. The method can take into account the piecewise continuous regions of the cutting that is attributed to the helix angle and the pitch variations between two subsequent teeth along the length of the axis. The piecewise character related to cutting force is deeply analysed and the effective depth of cut which seriously influences the maximum cutting force is discussed as well as its expression. Finally, a series of cutting tests and simulations are carried out to validate the present method.
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